So, the latest on my Panel Van:
This past Sunday (Aug 2) Bruce and I went to one of our usual area C&C type gatherings. As we got there the clutch pedal started feeling a bit softer than usual and would need double-pumping to go into reverse or first. I forgot to check the clutch master before we left and part way home I lost the clutch completely - totally soft pedal. We got it into the parking lot of a Dollar General and sure enough, the master was almost empty. I had to get a tow back home - thankfully I have roadside assistance with my Hagerty insurance on it. While waiting for the tow truck, I checked the system carefully: the master was dry; I have stainless flex line from the master to the slave and it was fine; there was leakage from the dust cap of the slave. I ordered two replacements (one for a spare) from Britich Parts Northwest and they are shipping today.
While waiting for parts to fix the clutch issue, I decided to go ahead with a few other tasks. 1) The van has 7.5" front disk brakes, but has been still using the original non-spacered rear drums. I have a 3/4" spacer kit from another Mini project (the white Moke I think) and I installed it today. I pulled the rear hubs off; tapped out the old studs: tapped in the new, longer studs; repacked the bearings; and put it all back together. 2) Next is getting it set up for flat-towing. I'll get a tow bar from Harbor Freight and an 'L' bar and 1/2" grade-8 bolts from Lowes to make the mount on the front, under the bumper. 3) I also decided to do a couple of cosmetic enhancements that I have been contemplating for a while - adding interior trim panels to the bottom half of the inside of the rear doors, adding trim panels over the 'C' pillars framing the rear doors to cover the exposed backs of the tail lights, and adding the exterior wood kit used on the MK-I/MK-II Estates.
I contacted an outfit in the UK that makes the wood kits that Bruce recommended as they had the best price and are known for their quality kits for the Morris Minor Estates. I have a Mini wood kit on order from them: £920 for the kit and another £140 for shipping was the quoted cost - about $1500 (which is about the same as I paid for a kit from a different supplier 24 years ago).
I'll make my own templates for the interior trim panels then use some leftover 1/4" paneling to make them and cover with upholstery vinyl that matches the reset of the interior.
Michael, you might consider getting a local welder to help with your upcoming flat tow rig by adding additional bracing and generally just strengthening everything. There are plenty of small welding shops and even individual welders out in the country who would love to help with a small simple project like that.